Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Kia Sorento owners, lightly cleaned up (personal details are redacted by NHTSA).
Oct, 2016 - I am the orignal owner of the vehicle and had maintained regular maintainence on the vehicle. I had just put $700 of new tires on vehicle and had a routine oil change and fluid check before we left for our vacation. I never had any issues with the vehicle and I still own. The vehicle does not run but I wanted to know what started the fire. My daughter and I were headed out of town for a week, about 200 miles into the commute the front of the vehicle began to smoke from under the hood, we were traveling at 55-60 MPH. As I was exiting the 421 highway flames began coming out from around hood and the paint on the hood began to bubble up due to heat. I immediately called the fire dept, as I was driving, pulled onto the shoulder and immediately removed my daughter and our belongings from the vehicle and distanced ourselves from the vehicle. …
Tl* the contact owns a 2004 Kia Sorento. Within less than 30 days of owning the vehicle, the contact stated that the fuel gauge on the instrument cluster continued to indicate full whether the contact refueled the vehicle or not. Also, when the air conditioner was turned off, smoke emitted into the interior of the vehicle and under the hood. The contact exited the vehicle and lifted the hood to fan away the smoke. The contact drove the vehicle to her job. Another consumer called the fire department because the vehicle erupted into flames. The fire department extinguished the flames. Neither a fire nor a police report was filed. The approximate failure mileage was 107,000. The manufacturer was notified of the failure.
Tl* the contact owns a 2004 Kia Sorento. While stationary, the vehicle caught fire without warning. The contact extinguished the fire. There were no injuries and a police report was not filed. The manufacturer was made aware of the issue. The failure mileage was 170,000.
Driving down the road and all of a sudden I have no power and can not go over 25 MPH. How safe is that on the highway, especially as I am driving with my kids!!!?? This has happened twice. The 1st time, it self corrected when I went to take it to the dealer to look at. This time, it has not. The lights constantly go off and on at any moments notice (real safe while driving at night)- and remain off for great lengths of time. I have had to replace the fuse that controls the fan in the engine twice already. I would shut the car off and the fan would not turn off unless I popped the hood and pulled the fuse myself and pocketed it until it was time to drive again. Not to mention major rust issues on the body of the vehicle. The cosmetic I can deal with, the losing power while on the highway I cannot. It is just a matter of time until someone is very seriously injured, or killed. …
I bought my 04 Sorento from my aunt who was the only owner. It had a power steering issue at that time which took several attenpts to fix. About a month later we we visiting family and had to turn around. Upon stopping we noticed smoke from the engine compartment so I grabbed my 4 y/o daughter out of the car and by boyfriend opened the hood to find a small fire on opposite side fro where battery is. Once fire was put out we drove .5 miles on a city rd to family. The power steering was gone at that time as well. 10/13/19 - the directional worked all day and come night time when I came out from the store and started vehicle they did not work. The next day they worked finehowever, on 10/14/19 - I started the car in am and there was a squeaky belt. I hit the gas pedal quickly and noise went away. …
I was driving approximately 35-40 MPH and my car suddenly lost power with all the dash lights briefly coming on (battery, oil, etc.). Fortunately I was close to a side street and was able to make a hard turn and coast to the curb. I waited a minute and was able to restart the vehicle. I drove home and there was one more incident when the car started to lose power (lights dimmed) however I pushed on the gas and it powered up again. I have had the lights dim and the car seemingly lose power several times. Just prior to this the car typically hesitates when you are going full speed and then the dimming occurs. I've had my car idle at stop signs and at train crossings and have not experienced any power loss. It always seems to happen while driving 35-40 MPH or more. I've had it happen while driving 60-70 MPH on the highway. …
200 miles from home, out of the blue, car acted like it was misfiring then lost power and died on highway at highway speeds. Car would not turn over or crank. Called tow truck to bring vehicle home for $490.00 and mechanic came out and hooked up machine to it and code came out crankshaft position sensor system. Check engine light wasn't on at all, until we got it home and it started up like no problem, but then died again. Weren't the crankshaft bolts already recalled and fixed?! Maintenance schedule always kept up to date and wouldn't you know, happened one month to the day that my extended warranty expired! Still haven't had it to shop, can't afford to bring it in after having it towed 200 miles, others thinks it can be fuel filter/pump or the brain, ECM. Who knows. Sitting with no vehicle is so much fun, thanks, Kia!
Was driving down the road at 55 power steering went car lost power lights went crazy car shut down. I almost wrecked harmonic balancer fell into pieces all pulley belts and pin have to be replaced. I just got this car I have a payment on it. Going to cost 1200 to fix. This is on top of it sputtering and spottying. Replace head lights the radio glitches the air bag light is on all the time and if u turn the interior dash lights up it turns the interior lights on.over drive button does not work and transmission lags... I have read al these complaints over and over again why isn't anyone forcing a recall? These are serious issues I almost got rear ended and the electrical problem could cause fire.... Someone is going to end up very hurt if Kia is not forced to fix these. Could u imagine this happening on a thru way?
Picked up vehicle after having rear support bearings repaired driving back home at 65mph on I-35/texas 410 east started to experience strong smell of exhaust fumes in passenger compartment. During drive home started to rain, activated wipers, drivers side wiper blade fell off during rainstorm had to open driver side window to navigate! Upon arrival at home noticed, smoke coming from engine compartment (passengers side) and smoke underneath vehicle from catalytic converter. Looked underneath vehicle and catalytic converter, was smoking, inside engine compartment a hose at the rear of the engine compartment (sorry not a mechanic) had a hole in it and was smoking also? Vehicle has not been driven since 12/7/12, vehicle was purchased 10/4/12, has limited warranty.
I purchased my car threw a local dealership aap. 8 mo. Ago it had 27,000 at the time of purchase. On 8-4-08 the vehicle had 34,000 miles. I was driving at a speed of app.40 mi. An hour when the car started smoking from the engine the smoke got thicker . I quickly pulled over into a small parking lot shut off the car + jumped out of the car with my son. In a matter of seconds the car was in flames. After that there was a hose that fell down under the car + was shooting flames from that too. The fire department came + put it out. The dash was caved in .the car was totaled. I reported this to the dealership + Kia corporation. They listened to my complaint with no result and would not take any responsibility for. It . Buyers beware.
Engine complaints in other Sorento years
Frequently asked questions
How common are engine problems on the 2004 Kia Sorento?
NHTSA has 92 complaints about the engine & cooling of the 2004 Kia Sorento, 42% of the model year's 220 complaints. The component named most often is engine (12 mentions).
Is there a recall for 2004 Kia Sorento engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Kia Sorento. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Kia Sorento engine problems start?
Half of the complaints with a recorded mileage happened before about 92,000 miles, and 2% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 7 fires and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.